This document provides guidance on improving yarn realization and controlling wastes in textile mills. It discusses calculating expected yarn realization based on factors like trash content and machine type. Norms for different types of wastes like blowroom droppings, card waste, comber noil, and yarn waste are provided. Measures to control process and reusable wastes are described. Maintaining invisible loss below 0.5% and usable waste below 5% is recommended. A 4-step approach is outlined to compare actual performance to expectations and address deviations through analysis and corrective actions.
The document discusses the roving frame machine, which comes after the draw frame in the spinning process. The roving frame drafts sliver from draw frame cans into a thin roving strand and applies a light twist. It operates by drafting the sliver, guiding it through the flyer to apply twist, and winding the roved strand onto bobbins. While complicated, the roving frame produces packages of roving suitable for input to the ring frame. Efforts to eliminate this step have not succeeded due to the high drafts required in ring frames.
The document describes a modern blowroom line consisting of machines from Rieter, including a bale opener, pre-cleaner, homogeneous mixer, precision blender, storage and feeding machine, condenser, card, and sliver coiler. It provides details on the functions of the Rieter bale opener, pre-cleaner, mixer, blender, storage machine, and condenser and card, which work together to open, clean, blend, feed, and condense cotton fibers into sliver in the blowroom process.
The document discusses the roving frame machine used in textile manufacturing. It begins by explaining the necessity of the roving process and the objectives of the roving frame. The key parts and operating zones of the machine are then described, including the creel, drafting arrangement, twist insertion via the flyer and spindle, and winding of roving onto bobbins. The document provides details on the operating sequence, process parameters like draft and twist levels, and the mechanical drive systems used in the machine.
This document discusses the objectives, operating principles, and components of a draw frame used in yarn production. The main objectives of a draw frame are equalizing fiber distribution, parallelizing fibers, blending fibers, and removing dust. It operates by drafting multiple sliver feeds together using roller pairs with differential speeds. Key components discussed include the creel, drafting arrangement, dust removal, coiling, and monitoring/auto-leveling systems.
The document discusses various aspects of automatic loom mechanisms, including:
1. It describes different types of weft replenishment mechanisms like mechanical, electrical, and photoelectric feelers and how they work to automatically detect when the weft yarn is running low and trigger a change.
2. It explains different weft patterning motions like weft mixing, drop box, and circular box motions that allow inserting different weft yarns to create patterns.
3. It provides details on how circular box and weft mixing motions work through lever mechanisms to rotate the boxes and change the inserted weft yarn every other pick.
A roving frame produces rovings of cotton and synthetic fibers through a process of drafting, twisting, and winding. It attenuates sliver through multiple drafting zones to form rovings of the required count. A flyer inserts twist into the roving as it is wound onto bobbins. Modern roving frames can achieve higher production rates through increased flyer speeds up to 1400 rpm and delivery speeds up to 40 m/min. They also have improved drafting systems and flyer designs for better fiber control and a wider draft range.
This document provides information about fancy yarns from Amsler Tex. It defines fancy yarn as having varied characteristics like thickness, color, and raw material that give fabrics a unique aesthetic. It then lists and describes different types of fancy yarns that can be produced using Amsler devices, including slub yarn, multi-count yarn, and multi-twist yarn. The document also explains concepts like the working principles of drafting and twisting systems, yarn measurement, effect coding, and how to simulate fabrics digitally before production.
The winding process involves transferring yarn from a smaller package to a larger package. There are two main objectives - to convert a smaller package into a larger package containing a long length of yarn, and to remove impurities from the yarn. The basic mechanisms of the winding process are unwinding, tensioning, yarn clearing, package building, and lubrication. Tensioning devices like multiplicative, additive, and disc types are used to provide the required winding tension. Yarn clearer devices remove faults from the yarn like thick and thin places. Package formation involves winding the yarn around the package using either a spindle or drum winder to build the package.
The document discusses the roving frame machine, which comes after the draw frame in the spinning process. The roving frame drafts sliver from draw frame cans into a thin roving strand and applies a light twist. It operates by drafting the sliver, guiding it through the flyer to apply twist, and winding the roved strand onto bobbins. While complicated, the roving frame produces packages of roving suitable for input to the ring frame. Efforts to eliminate this step have not succeeded due to the high drafts required in ring frames.
The document describes a modern blowroom line consisting of machines from Rieter, including a bale opener, pre-cleaner, homogeneous mixer, precision blender, storage and feeding machine, condenser, card, and sliver coiler. It provides details on the functions of the Rieter bale opener, pre-cleaner, mixer, blender, storage machine, and condenser and card, which work together to open, clean, blend, feed, and condense cotton fibers into sliver in the blowroom process.
The document discusses the roving frame machine used in textile manufacturing. It begins by explaining the necessity of the roving process and the objectives of the roving frame. The key parts and operating zones of the machine are then described, including the creel, drafting arrangement, twist insertion via the flyer and spindle, and winding of roving onto bobbins. The document provides details on the operating sequence, process parameters like draft and twist levels, and the mechanical drive systems used in the machine.
This document discusses the objectives, operating principles, and components of a draw frame used in yarn production. The main objectives of a draw frame are equalizing fiber distribution, parallelizing fibers, blending fibers, and removing dust. It operates by drafting multiple sliver feeds together using roller pairs with differential speeds. Key components discussed include the creel, drafting arrangement, dust removal, coiling, and monitoring/auto-leveling systems.
The document discusses various aspects of automatic loom mechanisms, including:
1. It describes different types of weft replenishment mechanisms like mechanical, electrical, and photoelectric feelers and how they work to automatically detect when the weft yarn is running low and trigger a change.
2. It explains different weft patterning motions like weft mixing, drop box, and circular box motions that allow inserting different weft yarns to create patterns.
3. It provides details on how circular box and weft mixing motions work through lever mechanisms to rotate the boxes and change the inserted weft yarn every other pick.
A roving frame produces rovings of cotton and synthetic fibers through a process of drafting, twisting, and winding. It attenuates sliver through multiple drafting zones to form rovings of the required count. A flyer inserts twist into the roving as it is wound onto bobbins. Modern roving frames can achieve higher production rates through increased flyer speeds up to 1400 rpm and delivery speeds up to 40 m/min. They also have improved drafting systems and flyer designs for better fiber control and a wider draft range.
This document provides information about fancy yarns from Amsler Tex. It defines fancy yarn as having varied characteristics like thickness, color, and raw material that give fabrics a unique aesthetic. It then lists and describes different types of fancy yarns that can be produced using Amsler devices, including slub yarn, multi-count yarn, and multi-twist yarn. The document also explains concepts like the working principles of drafting and twisting systems, yarn measurement, effect coding, and how to simulate fabrics digitally before production.
The winding process involves transferring yarn from a smaller package to a larger package. There are two main objectives - to convert a smaller package into a larger package containing a long length of yarn, and to remove impurities from the yarn. The basic mechanisms of the winding process are unwinding, tensioning, yarn clearing, package building, and lubrication. Tensioning devices like multiplicative, additive, and disc types are used to provide the required winding tension. Yarn clearer devices remove faults from the yarn like thick and thin places. Package formation involves winding the yarn around the package using either a spindle or drum winder to build the package.
Find out the production of lap former machine in kgAmit Biswas
The document contains 3 problems related to calculating production rates of various textile machines.
The first problem calculates the daily production in kg of a lap former machine given various parameters like delivery speed, feed weight, draft, and efficiency.
The second problem calculates the 8-hour production in kg of a modern speed frame machine based on flyer speed, hank size, threads per inch, draft, number of flyers, and efficiency. It also suggests increasing production.
The third problem calculates (1) the hourly production in kg of a combing machine given parameters like lap weight, feed per nip, nips per minute, number of heads, noil percentage, and efficiency, and (2) the
The document discusses rotor spinning technology. It describes the key tasks of a rotor spinning machine including opening fibers, cleaning, homogenizing, combining, ordering, improving evenness, imparting strength, and winding. It provides a historical overview of rotor spinning development from the 1930s to present day. It then details the major components and processes involved, including fiber feeding, separation and transport, fiber collection and alignment on the rotor, yarn formation through twist insertion, and yarn take-off and winding. The principles of rotor spinning and factors that influence yarn twist and quality are also summarized.
The compact spinning is a process where fiber strand drawn by drafting system is condensed before twisting it.Following methods are used by machine manufacturers to condense the fiber strand.
1. Aerodynamic condensing.
2. Mechanical condensing.
3. Magnetic condensing.
Compact spinning has a promising future because of the higher production and improved quality of compact yarns
The document discusses the blow room process in the textile industry. The blow room's main tasks are to open raw material into fine tufts, remove most impurities and dust, and provide a good blend. This must be done with careful treatment of the raw material, maximum material utilization, and optimum quality. The blow room consists of a sequence of different machines for opening, cleaning, and blending arranged in series. Each machine provides optimal performance for its position in the line. Proper machine selection and treatment of raw material in the blow room are important as errors cannot be corrected downstream.
The yarn realization is the most important factor to assess the technical performance and profitability of spinning mills. Yarn realization means conversion of raw material in percentage terms into finished yarn. This articles described What are the key factors affecting yarn realization and how to manage it.
This document discusses the combing process used in spinning mills to improve cotton fiber characteristics. It describes how combing removes short fibers and impurities through the actions of different combing elements like the top comb and nippers. The goal is to extract unusable fibers as noil waste while minimizing good fiber losses. The document provides details on combing machine components, the combing cycle, production calculations, and factors that influence the noil percentage. Overall, it serves to explain how combing upgrades raw cotton material to produce smoother, stronger yarn with fewer imperfections.
1. Carding is the process of reducing tufts of entangled fibers into a filmy web of individual fibers using machines called cards. There are three main types of cards used for cotton, wool, and man-made fibers.
2. The carding process opens fibers, removes impurities, disentangles neps, blends fibers, orients fibers, and forms slivers for further processing. It transforms a fiber batt into a uniform web of individual fibers.
3. Fiber batts are fed to the carding machine using either a lap feed system or a flock feed system. The chute feed system aims to feed a fiber sheet of uniform packing density and linear density.
The document discusses the key processes that take place in the blowroom of a yarn production facility. These include opening bales of fiber, cleaning the fiber through pre-cleaning and fine cleaning, removing dust, blending different fiber types, and evenly feeding the prepared fiber to the carding process. The goal of blowroom processes is to prepare fibers for subsequent processing while minimizing fiber loss and maintaining fiber quality.
Cotton is a natural fibre available easily and abundant quantity. It is a most suitable fibre for textile spinning & clothing due to it’s good spinnability & human friendly characteristics. As cotton is a natural fibre hence it’s properties also affected with several other factors which create variation in fibre properties, these variations also affect spinning processes & it’s products Quality in multi dimensions. Each fibre characteristic impact individually and collectively on spinning process or at ultimate product quality. Revolutionary changes observed in last two decade in the field of spinning machineries where processing speeds greatly increased to enhance production rate. Not only production rate of spinning machines increased but speeds of it’s downstream processes also increased simultaneously which requires better quality of yarn for smooth process and without any interruption to get the maximum efficiency. Hence now it is most important to co-relate fibre properties with respect to it’s consumer process competency. In this article we will discuss the different cotton properties and it’s impact on spinning process and product quality in present prospective and will try to minimize the impact of poor fibre properties on process or product Quality through better Mixing plan selection.
The document describes a multiphase loom assignment submitted by 6 students. It provides details on the mechanisms of circular and flat multiphase looms. Circular looms use two warp beams, closed reeds to spread the warp circularly, and electromagnetic shuttles that follow a circular path. Flat looms use positive weft carrier drives and rotating reeds for beat-up. The document also outlines features such as medium fabric production and use of split harnesses for shedding.
This document discusses the rapier loom and rapier weaving. It begins by defining a rapier loom as one that uses a rapier to pull the weft yarn across the loom. It can use a single or double rapier system. It then describes the key components and functioning of single and double rigid and flexible rapier systems. It also discusses different weft insertion principles like Dewas and Gabler systems as well as rapier drives, features of modern rapier looms, selvedge formation, weft insertion rates, and equations for calculating weaving production rates.
This document discusses testing methods for pilling and abrasion resistance of fabrics. It describes that pilling is the formation of small balls of entangled fibers on fabric surfaces due to rubbing, and is influenced by fiber properties like strength and stiffness. Methods to measure pilling include objective counting/weighing of pills or subjective comparison to standards. Tests for pilling include the ICI pilling box method and Martindale abrasion tester. Abrasion resistance depends on fiber type, properties, yarn twist, and fabric structure, and is measured using the Martindale abrasion tester by recording cycles until thread breakage. Grading scales are used to assess levels of pilling and abrasion damage.
The document discusses limitations of cam shedding systems when weaving designs with high numbers of picks in the repeat. For a 10-pick repeat design, 10 cams would be required, rotating at 1/10 the speed of the crank shaft. This results in a small dwell period of 48 degrees for each pick. As the number of picks increases, the cam contour becomes steeper, reducing the effective force on the follower and requiring higher operating forces. One solution is increasing the cam diameter to reduce the steepness of the cam contour, but this increases power needs and space requirements.
Analysis of rejected ring cops in autoconer winding machineTaukir Kabir Tusar
This document discusses the analysis of rejected ring cops in an autoconer winding machine. It begins with an introduction that describes ring cops, rejected ring cops, and the aim of analyzing the causes of cop rejections. The document then covers literature related to winding, common faults in winding, and reasons for faulty ring cops being rejected. It describes the experimental work, including collecting sample cops, quality tests performed, and identified causes of rejection such as count variation, product type variation, low cop content, and excessive neps. The goal is to understand the sources of rejections in order to reduce rejection rates.
Open-end spinning or rotor spinning is a technology for creating yarn without using a spindle. It separates fiber slivers into single fibers using an air stream and deposits them onto a collecting surface where they are twisted into yarn as it is drawn off. The principle is similar to a clothes dryer where individual sheets can be pulled out while twisting together. Fibers are fed onto the collecting surface which is continuously moving, aligning the fibers and twisting them into a thread that is wound onto a bobbin. Open-end spinning allows internal fiber stresses to relax and imparts twist directly onto the yarn end rather than drafting fibers. This makes the process faster and less labor intensive than ring spinning.
This document discusses ring spun yarn production. It provides details on the production process including bale management, blow room operations, carding, drawing, combing, roving using a simplex machine, ring spinning, autoconing, heat setting, and packing. Production parameters are given for 24s, 30s, and 40s ring spun yarn as well as 24s and 30s combed yarn. The document provides a comprehensive overview of the ring spinning process from raw cotton to finished yarn.
Importance, Effect & Testing of Yarn EvennessAmirul Eahsan
This document discusses irregularity or unevenness of fiber, which refers to variations in mass per unit length of a fiber assembly. It describes two common methods for measuring irregularity - the irregularity U% and the coefficient of variation C.V%. Several methods for measuring fiber irregularity are outlined, including visual inspection, cutting and weighing, and various testing machines like the Uster Evenness Tester and photoelectric testers. Irregular fibers can affect yarn strength, fabric appearance, and dyeing/finishing. Maintaining low irregularity is important for quality control in textile production.
Fabric Manufacturing Engineering, All Experiment Submission.pdfT. M. Ashikur Rahman
The tappet shedding mechanism uses tappets attached to a bottom shaft to raise and lower heald shafts, forming a shed for the shuttle to pass through. There are two main types - negative tappet shedding, where the tappet controls only one movement of the heald shaft and an external device returns it, and positive tappet shedding where the tappet controls both upward and downward movement. The tappet rotates and strikes a bowl connected to a treadle lever, moving the heald shaft up or down depending on the type of tappet shedding. Tappet shedding can produce basic weaves but is limited in complexity compared to other shedding mechanisms.
The document discusses the carding process which involves opening, cleaning and assembling fibers into a sliver through different sections of a carding machine like feed, licker-in, cylinder and doffer. It explains the objectives, necessities and zones of carding along with details of components like types of clothing, their functioning and settings that are important for quality carding. The document also covers developments in carding technology and types of drives used in modern carding machines.
This document is a project report submitted by three students - Md. Ahad Khan, Muhammad Abdullah Al - Mamun, and Mostafizur Rahman - from the Department of Textile Engineering at Daffodil International University on studying sampling at a garments industry. The project was supervised by Dr. Md. Mahbubul Haque and co-supervised by Md. Mominur Rahman from the same department and university.
1. The document defines various textile terms and definitions related to fibers, yarns, fabrics and processes. It discusses terms like abrasion, acid dye, acrylic, affinity, ageing, alpaca fiber, American cloth, angora fabric, aramid fiber and many others.
2. Key processes defined include bleaching, blending, beaming, dyeing methods like beam dyeing and bale dyeing. Fabric constructions addressed are patterns, weaves like balance weave. Quality aspects covered are imperfection index, micronaire, breaking load and elongation.
3. The document provides a comprehensive glossary of technical textile industry terms related to fibers, yarns, fabrics
Find out the production of lap former machine in kgAmit Biswas
The document contains 3 problems related to calculating production rates of various textile machines.
The first problem calculates the daily production in kg of a lap former machine given various parameters like delivery speed, feed weight, draft, and efficiency.
The second problem calculates the 8-hour production in kg of a modern speed frame machine based on flyer speed, hank size, threads per inch, draft, number of flyers, and efficiency. It also suggests increasing production.
The third problem calculates (1) the hourly production in kg of a combing machine given parameters like lap weight, feed per nip, nips per minute, number of heads, noil percentage, and efficiency, and (2) the
The document discusses rotor spinning technology. It describes the key tasks of a rotor spinning machine including opening fibers, cleaning, homogenizing, combining, ordering, improving evenness, imparting strength, and winding. It provides a historical overview of rotor spinning development from the 1930s to present day. It then details the major components and processes involved, including fiber feeding, separation and transport, fiber collection and alignment on the rotor, yarn formation through twist insertion, and yarn take-off and winding. The principles of rotor spinning and factors that influence yarn twist and quality are also summarized.
The compact spinning is a process where fiber strand drawn by drafting system is condensed before twisting it.Following methods are used by machine manufacturers to condense the fiber strand.
1. Aerodynamic condensing.
2. Mechanical condensing.
3. Magnetic condensing.
Compact spinning has a promising future because of the higher production and improved quality of compact yarns
The document discusses the blow room process in the textile industry. The blow room's main tasks are to open raw material into fine tufts, remove most impurities and dust, and provide a good blend. This must be done with careful treatment of the raw material, maximum material utilization, and optimum quality. The blow room consists of a sequence of different machines for opening, cleaning, and blending arranged in series. Each machine provides optimal performance for its position in the line. Proper machine selection and treatment of raw material in the blow room are important as errors cannot be corrected downstream.
The yarn realization is the most important factor to assess the technical performance and profitability of spinning mills. Yarn realization means conversion of raw material in percentage terms into finished yarn. This articles described What are the key factors affecting yarn realization and how to manage it.
This document discusses the combing process used in spinning mills to improve cotton fiber characteristics. It describes how combing removes short fibers and impurities through the actions of different combing elements like the top comb and nippers. The goal is to extract unusable fibers as noil waste while minimizing good fiber losses. The document provides details on combing machine components, the combing cycle, production calculations, and factors that influence the noil percentage. Overall, it serves to explain how combing upgrades raw cotton material to produce smoother, stronger yarn with fewer imperfections.
1. Carding is the process of reducing tufts of entangled fibers into a filmy web of individual fibers using machines called cards. There are three main types of cards used for cotton, wool, and man-made fibers.
2. The carding process opens fibers, removes impurities, disentangles neps, blends fibers, orients fibers, and forms slivers for further processing. It transforms a fiber batt into a uniform web of individual fibers.
3. Fiber batts are fed to the carding machine using either a lap feed system or a flock feed system. The chute feed system aims to feed a fiber sheet of uniform packing density and linear density.
The document discusses the key processes that take place in the blowroom of a yarn production facility. These include opening bales of fiber, cleaning the fiber through pre-cleaning and fine cleaning, removing dust, blending different fiber types, and evenly feeding the prepared fiber to the carding process. The goal of blowroom processes is to prepare fibers for subsequent processing while minimizing fiber loss and maintaining fiber quality.
Cotton is a natural fibre available easily and abundant quantity. It is a most suitable fibre for textile spinning & clothing due to it’s good spinnability & human friendly characteristics. As cotton is a natural fibre hence it’s properties also affected with several other factors which create variation in fibre properties, these variations also affect spinning processes & it’s products Quality in multi dimensions. Each fibre characteristic impact individually and collectively on spinning process or at ultimate product quality. Revolutionary changes observed in last two decade in the field of spinning machineries where processing speeds greatly increased to enhance production rate. Not only production rate of spinning machines increased but speeds of it’s downstream processes also increased simultaneously which requires better quality of yarn for smooth process and without any interruption to get the maximum efficiency. Hence now it is most important to co-relate fibre properties with respect to it’s consumer process competency. In this article we will discuss the different cotton properties and it’s impact on spinning process and product quality in present prospective and will try to minimize the impact of poor fibre properties on process or product Quality through better Mixing plan selection.
The document describes a multiphase loom assignment submitted by 6 students. It provides details on the mechanisms of circular and flat multiphase looms. Circular looms use two warp beams, closed reeds to spread the warp circularly, and electromagnetic shuttles that follow a circular path. Flat looms use positive weft carrier drives and rotating reeds for beat-up. The document also outlines features such as medium fabric production and use of split harnesses for shedding.
This document discusses the rapier loom and rapier weaving. It begins by defining a rapier loom as one that uses a rapier to pull the weft yarn across the loom. It can use a single or double rapier system. It then describes the key components and functioning of single and double rigid and flexible rapier systems. It also discusses different weft insertion principles like Dewas and Gabler systems as well as rapier drives, features of modern rapier looms, selvedge formation, weft insertion rates, and equations for calculating weaving production rates.
This document discusses testing methods for pilling and abrasion resistance of fabrics. It describes that pilling is the formation of small balls of entangled fibers on fabric surfaces due to rubbing, and is influenced by fiber properties like strength and stiffness. Methods to measure pilling include objective counting/weighing of pills or subjective comparison to standards. Tests for pilling include the ICI pilling box method and Martindale abrasion tester. Abrasion resistance depends on fiber type, properties, yarn twist, and fabric structure, and is measured using the Martindale abrasion tester by recording cycles until thread breakage. Grading scales are used to assess levels of pilling and abrasion damage.
The document discusses limitations of cam shedding systems when weaving designs with high numbers of picks in the repeat. For a 10-pick repeat design, 10 cams would be required, rotating at 1/10 the speed of the crank shaft. This results in a small dwell period of 48 degrees for each pick. As the number of picks increases, the cam contour becomes steeper, reducing the effective force on the follower and requiring higher operating forces. One solution is increasing the cam diameter to reduce the steepness of the cam contour, but this increases power needs and space requirements.
Analysis of rejected ring cops in autoconer winding machineTaukir Kabir Tusar
This document discusses the analysis of rejected ring cops in an autoconer winding machine. It begins with an introduction that describes ring cops, rejected ring cops, and the aim of analyzing the causes of cop rejections. The document then covers literature related to winding, common faults in winding, and reasons for faulty ring cops being rejected. It describes the experimental work, including collecting sample cops, quality tests performed, and identified causes of rejection such as count variation, product type variation, low cop content, and excessive neps. The goal is to understand the sources of rejections in order to reduce rejection rates.
Open-end spinning or rotor spinning is a technology for creating yarn without using a spindle. It separates fiber slivers into single fibers using an air stream and deposits them onto a collecting surface where they are twisted into yarn as it is drawn off. The principle is similar to a clothes dryer where individual sheets can be pulled out while twisting together. Fibers are fed onto the collecting surface which is continuously moving, aligning the fibers and twisting them into a thread that is wound onto a bobbin. Open-end spinning allows internal fiber stresses to relax and imparts twist directly onto the yarn end rather than drafting fibers. This makes the process faster and less labor intensive than ring spinning.
This document discusses ring spun yarn production. It provides details on the production process including bale management, blow room operations, carding, drawing, combing, roving using a simplex machine, ring spinning, autoconing, heat setting, and packing. Production parameters are given for 24s, 30s, and 40s ring spun yarn as well as 24s and 30s combed yarn. The document provides a comprehensive overview of the ring spinning process from raw cotton to finished yarn.
Importance, Effect & Testing of Yarn EvennessAmirul Eahsan
This document discusses irregularity or unevenness of fiber, which refers to variations in mass per unit length of a fiber assembly. It describes two common methods for measuring irregularity - the irregularity U% and the coefficient of variation C.V%. Several methods for measuring fiber irregularity are outlined, including visual inspection, cutting and weighing, and various testing machines like the Uster Evenness Tester and photoelectric testers. Irregular fibers can affect yarn strength, fabric appearance, and dyeing/finishing. Maintaining low irregularity is important for quality control in textile production.
Fabric Manufacturing Engineering, All Experiment Submission.pdfT. M. Ashikur Rahman
The tappet shedding mechanism uses tappets attached to a bottom shaft to raise and lower heald shafts, forming a shed for the shuttle to pass through. There are two main types - negative tappet shedding, where the tappet controls only one movement of the heald shaft and an external device returns it, and positive tappet shedding where the tappet controls both upward and downward movement. The tappet rotates and strikes a bowl connected to a treadle lever, moving the heald shaft up or down depending on the type of tappet shedding. Tappet shedding can produce basic weaves but is limited in complexity compared to other shedding mechanisms.
The document discusses the carding process which involves opening, cleaning and assembling fibers into a sliver through different sections of a carding machine like feed, licker-in, cylinder and doffer. It explains the objectives, necessities and zones of carding along with details of components like types of clothing, their functioning and settings that are important for quality carding. The document also covers developments in carding technology and types of drives used in modern carding machines.
This document is a project report submitted by three students - Md. Ahad Khan, Muhammad Abdullah Al - Mamun, and Mostafizur Rahman - from the Department of Textile Engineering at Daffodil International University on studying sampling at a garments industry. The project was supervised by Dr. Md. Mahbubul Haque and co-supervised by Md. Mominur Rahman from the same department and university.
1. The document defines various textile terms and definitions related to fibers, yarns, fabrics and processes. It discusses terms like abrasion, acid dye, acrylic, affinity, ageing, alpaca fiber, American cloth, angora fabric, aramid fiber and many others.
2. Key processes defined include bleaching, blending, beaming, dyeing methods like beam dyeing and bale dyeing. Fabric constructions addressed are patterns, weaves like balance weave. Quality aspects covered are imperfection index, micronaire, breaking load and elongation.
3. The document provides a comprehensive glossary of technical textile industry terms related to fibers, yarns, fabrics
Yarn realisation is one of the Key Performance parameter for achieving profits in a Spinning mills.In these slides WINSYS SMC explains in detail along with its case studies.
This document provides a summary of a concept renewal for the Sitra.fi website by The Design Group in September 2010. The goals are to redefine, restructure, and redesign Sitra.fi to better engage users and provide value. A new concept is proposed with 5 key themes: 1) clear positioning of Sitra, 2) improved user experience, 3) up-to-date organized content, 4) facilitating conversation and networking, and 5) educating users. The content will be structured to support different levels of user involvement from core to immersed. An iterative development process using frequent releases is recommended to refine the new platform based on openness and sharing best practices.
This document discusses common defects in fabric known as Barré and their causes. The main causes are fiber (70%), yarn count variation (10%), twist variation (10%), and hairiness (10%). Barré can be caused by variations in micronaire, maturity/fineness, and fluorescence between cotton bales. Specific issues that can lead to Barré include a difference in micronaire greater than 0.2 between mixes, and a coefficient of variation over 12% for micronaire within a mix. Blending cottons from different growth areas or varieties can also cause Barré due to differences in maturity and fineness. Variations in fluorescence readings between bale mixes and within mixes, as well as uneven card
The document provides background information on Azgard Nine, a textile company based in Pakistan. Some key points:
- Azgard Nine traces its origins to a family business established over four generations ago in 1886.
- It has grown to become a fully integrated textile and apparel solution provider, with operations including yarn production, denim weaving, and garment manufacturing.
- The company's vision is to become a major global fashion apparel company and retain its leadership position as the largest value-added denim producer in Pakistan.
- A financial analysis of Azgard Nine from 2005-2009 shows the company has generally managed its receivables and inventory efficiently, though days
1) The document summarizes a simulation project of a textile/apparel supply chain in Egypt. The objectives were to build a simulation model of a factory's supply chain and analyze the system, collect and analyze data, implement the simulation model, and test different scenarios.
2) Key aspects of the model include modeling 4 categories of entities, assigning service times, and extracting performance metrics from the SCOR model like cycle times. Scenarios tested include increasing production capacity and increasing raw material supply durations.
3) Future work includes adding cost aspects, improving the user interface, creating a more dynamic model, and increasing model accuracy.
This document discusses environmentally friendly techniques in textiles. It begins with an introduction to the large and growing textile industry in Bangladesh and the water pollution issues it causes. It then provides details on the typical textile manufacturing process and characteristics of textile wastewater. The document discusses various environmentally friendly wastewater treatment methods used in the textile industry, including physicochemical treatment plants, biological treatment plants such as activated sludge and membrane bioreactors, and low-tech solutions like aerobic and anaerobic ponds. It also presents case studies of wastewater treatment establishments in Bangladesh and discusses the benefits of membrane bioreactors compared to conventional biological units.
Research report of Kohinoor Textile MillsHamza Zuberi
This report is written on The Kohinoor Textile Mills Ltd(KTML) which is a part of The Kohinoor Mills Ltd (KML). From a cotton export house, the KML has grown into a premier business group of Pakistan with 5 listed companies, concentrating on 3 core businesses; Textiles, Cement and Power Generation.
The document discusses textile spinning and quality control processes. It describes the key steps in textile spinning which include: yarn production from staple fibers using drawing and twisting; filament yarn production by forcing fiber-forming substances through spinnerets. The main processes are: blowroom preparation, carding, drawing, roving and ring spinning. Quality is ensured through testing of raw materials and processes. Fiber properties like length, strength and uniformity are evaluated. Machines are also tested to minimize count variations and improve yarn evenness and strength in the final product.
December 28, 2013
Production Planning & Merchandising
30
Southeast University
Department of Textile Engineering
The document provides details about production planning and merchandising at two garment factories in Bangladesh: Padma Poly Cotton and FCI BD Ltd. It discusses the company profiles, production planning procedures, merchandiser responsibilities, and findings from internship reports on the topic. Key aspects of production planning and merchandising discussed include ratio breakdown, production line setup, SMV calculation, and the roles of merchandisers in design, cutting, sewing, and store sections.
Textile it is a flexible woven material consisting of a network of natural or artificial fibres often referred to as thread or yarn derived from animals, plants,minerals,synthetics Some chemicals hazardous to human health or the environment.
1.5 kg/kg of sized yarn
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Chapter-1
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Chapter 2
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Chapter 3
Surveying: Object Principles & Types of Surveying; Site Plans, Plans & Maps; Scales & Unit of different Measurements.
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Chapter 6
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How to-improve-yarn-realization-and-control-wastes
1. How to improve Yarn
realization and control
wastes?
D.Shanmuganandam
Assistant Director
The South India Textile Research Association
Coimbatore – 641 014
2. How to improve Yarn realization and
control wastes?
D.Shanmuganandam
Assistant Director
The South India Textile Research Association
Coimbatore – 641 014
1. INTRODUCTION
In the production economics of a spinning mill, yarn realisation plays a significant
role. To illustrate, in the prevailing cotton cost and yarn selling price, even an 1%
improvement in yarn realisation would lead to a saving of Rs 20 lakhs per year for a
30000 spindle mill manufacturing 40s yarn.
Two decades ago, SITRA had brought out a publication on yarn realisation and
process waste control. During this intervening period, remarkable changes have taken
place in the industry with regard to technology of machinery, yarn quality and
workers’ efficiency. Keeping the above in mind, the formulae for estimating yarn
realisation and norms for different categories of wastes have been updated and
presented in this article.
This article also deals with various measures necessary to improve yarn realisation
and control wastes. Besides controlling process wastes such as blowroom and card
droppings, flat strips, comber noil, sweep waste and yarn waste, equal emphasis
should also be laid on the control of reusable wastes (soft waste) such as lap bits,
sliver bits, roving ends and pneumafil and roller waste. This is because, apart from
loss in production, reprocessing of soft wastes involves extra handling and
deteriorates yarn quality.
2. YARN REALISATION
Establishment of norms for wastes is a pre-requisite for a successful waste control in a
mill. Yarn realisation (YR) is largely governed by the level of trash in cotton,
expected yarn quality and type of machinery. Achievable yarn realisation can be
obtained using the following formulae:
A. For mills reusing the entire usable wastes in the same mixing
YR (%) = 97.5 – t – Wk – Wh for carded counts
Wc
= (100 – t – Wk) 1 – – Wh – 2.5 for combed counts
100
3. B. For mills not reusing the usable wastes in the same mixing
YR (%) = 97.5 – t – Wk – Wh – Wu for carded counts
Wc
= (100 – t – Wk) 1 – – Wh – Wu – 2.5 for combed counts
100
Where t = trash in mixing (%)
Wk = card waste (%)
Wc = comber noil (%)
Wh = yarn waste (%)
Wu = usable waste (%)
For example, for t = 3%, Wk = 7% and Wh = 0.5%, the expected yarn realisation is
87%. In the above case, if the mill produces combed yarn with a noil extraction of
18%, then the expected yarn realisation will be 70.8%. In both the cases, it is
assumed that the mill would reuse the usable wastes in the same mixing.
3. NORMS FOR WASTES
Norms for different categories of wastes are summarised in Tables 1 and 2.
Table 1 Norms for process waste and invisible loss
Type of waste Norms (%)
Blow room droppings Same as trash in cotton
Gutter/filter waste 1.0
Card waste (modern cards) 20s - 40s : 7.0
Above 40s : 6.0
Sweep wastea 1.0
Yarn waste
Conventional cone winding 0.1
Doubler winding 0.1
Ring doubling 0.1
TFO twisting 0.1
Auto winding
- with magazine feed 0.5
- with auto feed 0.8
Invisible loss 0.5
‘a’ includes suction fan wastes of draw frames, fly frames and humidification plant.
Table 2 Norms for usable waste (%)
Type of waste Lap feed Chute feed
Lap bits and card web 0.7 0.2
Sliver waste in drawing and fly frames 0.5 0.5
Waste at comber preparatory and combers 1.0 1.0
Roving ends 0.3 0.3
Pneumafil and roller waste (ring frames) 2.5 2.5
Total 5.0 4.5
4. For the method of consolidating waste, estimating invisible loss and checking the
accuracy of figures, reference may be made to SITRA monograph “Quality Control in
Spinning”, 1998.
4. PROCESS WASTE
4.1. Blow room
Amount of waste extracted in blow room is mostly determined by the trash level in
cotton. In modern blow room lines, greater importance is attached to the opening of
cotton than cleaning. Hence, cleaning efficiency of about 60% in cottons with high
trash content and 50% in cottons with low trash level can be considered to be quite
satisfactory in these lines. For good cleaning efficiency, the waste extracted in blow
room should be about the same as the trash in mixing. If, however, the cleaning
efficiency achieved is less than 50% – 60%, then the total waste extracted should also
be low. It should be ensured that the overall lint in waste is no more than 40% in
cottons with high amount of trash and 50% for cottons with low level of trash.
The expected lint loss can be estimated using the following formula:
(t – t L) 100
Wb = ……………… (1)
(100 – L)
(t – t L)
∴ L = 100 1 – ……………… (2)
Wb
Where
t = trash in mixing (%)
tL = trash in lap (%)
Wb = waste extracted in blow room (%)
L = % lint in waste
Illustrative Examples
1. Trash in mixing : 3.5%
Trash in lap : 1.5%
Waste extracted : 3.2%
Calculate the lint loss in waste.
Refer equation (2),
(t – t L)
Lint loss (L) = 100 1–
Wb
(3.5 –1.5)
= 100 1–
3.2
= 38%
2) Trash in mixing : 5%
Trash in lap : 2%
Expected lint loss : 40%
Estimate the amount of waste to be extracted in blow room
5. Refer equation (1),
(5 – 2) x 100
Wb =
(100 – 40)
= 5%
Presently, many mills are using Automatic Waste Evacuation System (AWES)
in blow room, cards and combers, which removes wastes from these machines either
continuously or intermittently. This system not only reduces the man power required
to collect and transport wastes but also helps to control the incidence of fly and fluff
generation in these departments and improves yarn quality, particularly short thick
faults.
In mills not equipped with filters in blow room, a proper estimate of gutter
waste should be made, since gutter cleaning is not done regularly at the end of every
month. The estimate of gutter waste could be made based on the quantum of waste
collected and number of days the blow room has worked.
4.2. Cards
Waste extracted in cards is usually in the range of 4% to 7% depending upon
the type of card and mixings. Between same type of cards and mixing, the waste %
should not vary more than ±0.5% from the average. The card waste is also governed
by the cleaning efficiency achieved in blow room. Thus, while assessing the waste,
combined waste extracted in blow room and cards should be taken into account. The
combined cleaning efficiency will be generally in the range of 90% to 98% with
modern cards. To illustrate, for 4% trash in cotton and 0.12% trash in sliver, the
combined cleaning efficiency is 97%.
4.3. Combers
Generally, all cottons respond well to combing for noil extraction up to 16%. For levels
beyond 16%, the law of diminishing returns operates and the improvement in yarn
quality is not commensurate with the additional cost of production. Higher levels of
waste should be extracted only in such cottons where combing performance is
satisfactory or where the end use requires yarns of very high quality. Under good
working, for every 1% increase in comber waste, yarn lea strength will increase by 1%
and evenness is expected to improve by 0.15 U%. Variation in noil % between
combers must be maintained within ±0.5% and between heads it must be within ±1.5%.
4.4. Yarn waste
Yarn waste in a spinning mill should not normally exceed 0.1% with
conventional cone winding. In the case of automatic cone winding, the yarn waste
generally varies from 0.5% in winders fitted with magazine feed to 0.8% in winders
with auto bobbin feed system. However, if the yarn under goes additional processes in
post spinning such as reeling, doubler winding and TFO twisting/ring twisting, the
waste would be somewhat higher. A high incidence of yarn waste, apart from leading
to a loss of Rs 6 to Rs 15 per spindle per year for every 0.1% waste, is an indication of
poor machinery condition and maintenance, and inappropriate work practices of
operatives. A number of factors such as vibrating spindles, spindles out of center, soft
cops, oil stain on yarn, improperly built cop bottom, yarn left over in cops during
winding and operatives using excess length while piecing, leads to high yarn waste. For
further information on yarn waste control, reference may be made to SITRA publication
“Measures to Control Hard Waste in Spinning” Vol.41, No.11, March 1996.
6. 4.5. Sweep waste
Sweep waste in all the departments of a spinning mill together should be
within 1%. A high sweep waste arises invariably due to operatives throwing away the
wastes like roller waste, lap bits, sliver bits, roving ends, etc. on the floor and
generation of fly and fluff. The fly frame and ring frame tenters should be provided
with hip bags and it should be ensured that the roller waste and roving ends are
deposited in the bags after piecing the broken ends. Good waste, if any, should be
picked before sweeping instead of sorting out the waste later. A high price fetched for
sweep waste would give an indication of the presence of good fibers in the waste.
5. INVISIBLE LOSS
Invisible loss in a spinning mill occurs due to a number of factors such as
short fibers (fluff) escaping from the departments, improper accounting of wastes
produced, weighment errors in cotton purchased and wastes sold, excess give away of
yarn and inaccuracies in the estimates of stock held in process. Since it would be
difficult to accurately assess the process stock, it is suggested that the invisible loss be
assessed only once in 4 months for control purposes. This will help in minimising the
variation in invisible loss due to errors in process stock estimate. From the data
compiled every month, a cumulative average could also be taken for control purpose.
However, not much importance should be given for estimates made from data less
than 4 months.
To maintain the invisible loss within 0.5%, mill should also ensure that
moisture content in the finished goods is at par with the level prevailed in cotton at the
time of purchase. For more details on invisible loss control, reference may be made
to SITRA Focus “How to Control Invisible Loss in Spinning Mills? – Case study”,
Vol.23, No.3, September 2005.
6. USABLE WASTE
By exercising good control over
end breaks in various machines
material handling and storage and
work practices of operatives
a mill could maintain the usable waste below 5%.
7. CONCLUSION
In many mills, there is good scope for improving yarn realisation and reducing
wastes (as revealed by inter-mill studies as well as consultancy studies by SITRA).
The following 4 steps would be helpful to improve yarn realisation.
Step 1: Calculate actual yarn realisation and different categories of wastes
Step 2: Using the formulae given in this article, estimate the expected yarn
realisation for the existing working conditions.
Step 3: Compare the actual yarn realisation with the expected value and actual
wastes with norms.
Step 4: Analyse the causes for deviation and initiate corrective action. Create
awareness among the workers and technical staff about the importance
of waste control. Good supervision and proper maintenance of
machinery would help to reduce the waste.
Source: The south Indian Textile Research Association, Coimbatore-641014, India,
http://www.sitra.org.in/default.aspx.
*****